SECTION
CONTENTS
MAINTENANCE
MA
•
PRECAUTIONS ANDPREPARATION
3
Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System) 3
Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System) 3
Special Service Tools 4
Commercial ServiceTool 4
PRE-DELIVERY INSPECTIONITEMS
5
GENERAL MAINTENANCE 6
PERIODIC MAINTENANCE (Exceptfor
Europe) 7
Engine andEmission ControlService 7
Chassis andBody Service 8
Maintenance UnderSevere DrivingConditions 9
PERIODIC MAINTENANCE (ForEurope) 10
Engine Oil
&
Minor Service 10
Engine andEmission ControlService 11
Chassis andBody Services 12
Maintenance UnderSevere Driving Conditions 13
RECOMMENDED LUBRICANTSANDFLUIDS 14
Lubricants andFluids 14
SAE Viscosity Number 15
Anti-freeze CoolantMixtureRatio 16
~ --ll
GA
I I
ENGINE MAINTENANCE 17
Checking DriveBelts 17
Changing EngineCoolant... 19
Checking CoolingSystem 21
Checking FuelLines 22
Changing FuelFilter 22
Cleaning andChanging AirCleaner Filter 23
Changing EngineOil 24
Changing OilFilter 24
Checking andChanging SparkPlugs 25
Checking IgnitionWires 26Changing
PositiveCrankcase Ventilation
(PCV) Filter 26
Checking EVAPVapor Lines 26
Checking OxygenSensor(02S)orHeated
Oxygen Sensor(H02S) 27
~ --ll
SR
I I
ENGINE MAINTENANCE 28
Checking DriveBelts 28
Changing EngineCoolant... 29
Checking CoolingSystem 31
Checking FuelLines 32
Changing FuelFilter 32
Changing AirCleaner Filter 33
Changing EngineOil 33
Changing OilFilter 34
Changing SparkPlugs(Platinum-tipped type)34
Checking IgnitionWires 35
Checking EVAPVapor
&
Purge Lines 36
Checking HeatedOxygen Sensor(H02S) 37
~_~ ..-JI
CD
I I
ENGINE MAINTENANCE
38
Manifold NutCheck 38
Checking DriveBelt 38
Changing EngineCoolant. 38
Checking CoolingSystem .40
Checking FuelLine .40
Changing AirCleaner Filter 41
Water Draining, FuelFilter Check and
Replacement 41
Changing EngineOil .41
Changing EngineOilFilter 42
Checking InjectionNozzle 43
Checking IdleSpeed .44
Replacing TimingBelt 44
PRE-DELIVERYINSPECTIONITEMS
Shown belowarePre-delivery InspectionItemsrequired forthe new vehicle. Itis recommended that
necessary itemsotherthanthose listedherebeadded, payingdueregard tothe conditions ineach
country.
Perform applicable itemsoneach model. Consult textofthis section forspecifications .
UNDER HOOD-engine off
o
Radiator coolantlevelandcoolant hosecon-
nections forleaks
o
Battery fluidlevel, specific gravityandcondi-
tions ofbattery terminals
o
Drive beltstension
D
Fuel filter forwater ordusts, andfuel lines
and connections forleaks
[] Engine oillevel andoilleaks
D
Clutch andbrake reservoir fluidlevel and
fluid lines forleaks
o
Windshield andrear window washerand
headlamp cleanerreservoir fluidlevel
D
Power steering reservoir fluidlevel andhose
connections forleaks
ON INSIDE ANDOUTSIDE
D
Remove frontspring/strut spacer(Ifapplica-
ble)
D
Operation ofall instruments, gauges,lights
and accessories
o
Operation ofhorn(s), wiperandwasher
[] Steering lockforoperation
[] Check airconditioner forgas leaks
o
Front andrear seats, andseat belts foroper-
ation
n
All moldings, trimsandfittings forfitand
alignment
[J
Allwindows foroperation andalignment
n
Hood, trunklid,door panels forfitand align-
ment
[1
Latches, keysandlocks foroperation
rl
Weatherstrips foradhesion andfit
[l
Headlamp aiming
I~ Tighten wheelnuts(Inc. inner nutsifapplica-
ble)
IJ Tire pressure (Inc.spare tire)
Il
Check frontwheels fortoe-in
IJ Install clock/voltmeter/room lampfuse(If
applicable)
~ Install deodorizing filtertoair purifier (If
applicable)
~ Remove wiperbladeprotectors (Ifapplicable)
UNDER
BODY
o
Manual transmission/transaxle, transferand
differential gearoillevel
D
Brake andfuel lines andoil/fluid reservoirs
for leaks
D
Tighten boltsandnuts ofsteering linkageand
gear box,suspension, propellershaftsand
drive shafts
~ Tighten rearbody boltsandnuts (Models with
wooden bedonly)
ROAD TEST
D
Clutch operation
D
Parking brakeoperation
[J
Service brakeoperation
D
Automatic transmission/transaxle shifttiming
and kickdown
[] Steering controlandreturnability
o
Engine performance
D
Squeaks andrattles
ENGINE OPERATING ANDHOT
D
Adjust idlemixture andspeed (andignition
timing*1)
n
Automatic transmission/transaxle fluidlevel
~ Engine idlingandstop knob operation (Diesel
only)
FINAL INSPECTION
n
Install necessary parts(outside mirror,wheel
covers, seatbelts, mat,carpet ormud flaps)
[1
Inspect forinterior andexterior metaland
paint damage
[] Check forspare tire,jack, tools (wheel
chock), andliterature
n
Wash, cleaninterior andexterior
"1: Not required onmodels withadirect ignition system
~ :Not appiicable tothis model.
•
MA-5
SLC0538
Water
inlet
Water
outlet ENGINE
MAINTENANCE [][]
Changing EngineCoolant (Cont'd)
14. Warm upengine tonormal operating temperature.
15. Run engine at2,500 rpmfor10seconds andreturn toidle
speed .
• Repeat 2or 3times. •
Wat~h coolant temperature gaugesoasnot tooverheat the
i
engme.
16. Stop engine andcool itdown.
• Cool down usingafan toreduce thetime.
17. Refill reservoir tanktoMax linewith coolant.
18. Repeat step15through step17two ormore times.
19. Warm upengine, andcheck forsound ofcoolant flowwhile
running enginefromidleupto4,000 rpmwith heater tem-
perature controlsetatseveral positions betweenCOOLand
HOT.
• Sound maybenoticeable atheater watercock.
20.
If
sound isheard, bleedairfrom cooling systembyrepeat-
ing steps 14through 17until coolant levelnolonger drops.
• Clean excess coolant fromengine.
CAUTION:
When heater unitisremoved orreplaced, refillengine coolant
as shown, removing heaterhoseatfeeding connector on
engine.
Checking CoolingSystem
CHECKING HOSES
Check hosesforimproper attachment andforleaks, cracks,
damage, looseconnections, chafinganddeterioration.
CHECKING RADIATORCAP
Apply pressure toradiator capwith captester tosee ifit is sat-
isfactory.
Radiator caprelief pressure:
Standard 78 -98 kPa
(0.78 -0.98 bar,0.8-1.0 kg/cm
2,
11-14 psi)
limit
59-98 kPa
(0.59 -0.98 bar,0.6-1.0 kg/cm
2,
9-14 psi)
MA-31